Composite fabric assembly

ABSTRACT

A composite fabric assemble having at least one layer of base fabric, to be worn adjacent to a user; is connected to a first layer of ballistic fabric which has portions thereof cut at least partially into strips of material. A second layer of ballistic fabric is connected to the first layer of ballistic fabric, and is punched at least partially therethrough to form at least one design or shape thereon, to improve the flexibility of the fabric assembly. Either the first layer of ballistic fabric or the second layer of ballistic fabric can be adjacently connected to and overlapping the base fabric, whereby the base fabric is covered.

This invention relates generally to a composite fabric assembly, and more particularly to an improved composite fabric assembly having spike and edge blade resistant properties for use with humans and animals, in the manufacture of protective garments and accessories which are lightweight, flexible, fire retardant, durable and reliable, and which can provide protection of body parts in addition to the head, neck, chest/torso region, as well as arms and legs.

DESCRIPTION OF THE PRIOR ART

It is well known that various stab resistant articles or garments, such as protective vests, have been worn by prison corrections officers and other types of security, military or law enforcement personnel, and have even been developed for working animals such as dogs or horses. Such spike resistant articles are designed to prevent bodily penetration as a result of stabbing or slashing from sharp objects or weapons. Unfortunately, these protective articles were generally rigid shields which were externally worn and were constructed of heavy, bulky and inflexible metal components such as titanium or other extremely hard metal alloys and rigid fabrics. The metallic and fabric composition of these cumbersome external vest shields must be of sufficient thickness, rigidity and strength to stop impacts imparted by an attacker, and limit coverage of critical body parts.

Disadvantageously, the bulk and rigidity of such protective vest garments rendered it uncomfortable to wear. It is known that some protective vests comprise 50 layers, front and back, of polymer matrix material (for a total of 100 layers), which renders such vests stiff, and having little flexibility. Furthermore, it is rather difficult for the wearer of a rigid vest to move and maneuver around quickly and easily which is important especially if the wearer is being attacked. Accordingly, such known puncture resistant articles often prove to be ineffective predominantly due to the fact that the potential wearer prefers not to wear the bulky torso shield, rather than tolerating its discomfort, as when used for extended periods such items can be hot and heavy.

Another, and perhaps a more significant problem with such types of rigid fabric and metallic alloy puncture resistant vests, is that they were not concealable. These known cumbersome shield vests were almost exclusively externally worn and even if they were not worn externally, the bulky nature of such articles make it obvious to a would be attacker that the wearer (corrections officer, etc.) is wearing a protective spike and edge blade resistant protective shield vest. Since the worn vest article cannot be concealed the potential attacker is more prone to stab or slash at a vital area away from the vest such as the lower abdomen, groin, neck or head area. Not only is any element of surprise on the part of the wearer removed by the unconcealed nature of such cumbersome rigid vests, it is highly impractical if not impossible for the undercover personnel to wear such bulky items, and even if used these items offer little to no protection of other body parts such as the arms and legs, damage to which can and do cause severe, life threatening wounds. For example, wounds to the femoral artery can and often kills the person, because there is no protective gear for this area.

Thus, there is a need to provide a light weight, flexible composite fabric assembly which is flexible, lightweight, fire retardant, durable, and which can provide protection to vulnerable body parts of humans and working animals, and which can be removed quickly and easily. There is a further need for a flexible composite fabric assembly which can provide protection of body parts, in addition to the chest/torso region, such as arms and legs. In this regard, the present invention substantially fulfills this need.

SUMMARY OF THE INVENTION

It is an object and advantage of the present invention to provide an improved spike and edge blade resistant composite fabric assembly having ballistic properties which is light weight, flexible, durable, thinner in profile by up to 50% of current 50 layer vests and which can provide protection to vulnerable body parts of humans and working animals, and which can be removed quickly and easily.

It is another object and advantage of the present invention to provide an improved spike and edge blade resistant flexible composite fabric assembly having ballistic properties which can provide protection of body parts in addition to the chest/torso region, such as arms, legs, neck and feet.

According to one aspect of the present invention, there is provided a composite fabric assembly comprising a composite fabric assembly comprising at least one layer of base fabric, the at least one layer of base fabric being constructed and arranged to be worn adjacent to a user; at least a first layer of ballistic fabric having portions thereof cut at least partially into strips of material; at least a second layer of ballistic fabric connected to the at least a first layer of ballistic fabric, and punched at least partially therethrough to form at least one design or shape thereon; and wherein either of the at least a first layer of ballistic fabric or the at least a second layer of ballistic fabric are adjacently connected to and overlapping the at least a first layer of base fabric whereby the at least one layer of base fabric is substantially covered.

According to another aspect of the present invention, there is provided a method for manufacturing a composite fabric assembly comprising providing at least one layer of base fabric; providing at least a first layer of ballistic fabric; and providing at least a second layer of ballistic fabric connected to the at least a first layer of ballistic fabric, and; cutting portions of the at least a first layer of ballistic fabric at least partially into strips of material; punching, at least partially therethrough, portions of the at least a second layer of ballistic fabric to form at least one design or shape thereon; and connecting either of the at least a first layer of ballistic fabric or the at least a second layer of ballistic fabric to the at least one layer of base fabric so as to be in an adjacent and overlapping relationship therewith, whereby the at least one layer of base fabric is substantially covered.

According to another aspect of the present invention, there is provided a method for assembling a composite fabric assembly for use in a protective garment or protective accessory comprising providing at least one layer of base fabric; providing at least a first layer of ballistic fabric; and providing at least a second layer of ballistic fabric connected to the at least a first layer of ballistic fabric,

cutting portions of the at least a first layer of ballistic fabric at least partially into strips of material; punching, at least partially therethrough, portions of the at least a second layer of ballistic fabric to form at least one design or shape thereon; connecting either of the at least a first layer of ballistic fabric or the at least a second layer of ballistic fabric to the at least one layer of base fabric so as to be in an adjacent and overlapping relationship therewith, whereby the at least one layer of base fabric is covered; and positioning the composite fabric assembly in the protective garment or protective accessory.

According to another aspect of the present invention, there is provided a protective garment or protective accessory constructed and arranged to receive a composite fabric assembly for protecting a body region of a wearer, the assembly comprising a) at least one layer of base fabric; b) at least a first layer of ballistic fabric having portions thereof cut at least partially into strips of material; c) at least a second layer of ballistic fabric connected to the at least a first layer of ballistic fabric, and punched at least partially therethrough to form at least one design or shape thereon, wherein either of the at least a first layer of ballistic fabric or the at least a second layer of ballistic fabric are adjacently connected to and overlapping the at least a first layer of base fabric, whereby the at least one layer of base fabric is covered; and whereby the protective composite fabric assembly is positioned within at least one pocket formed on a surface of the protective garment or protective accessory, or positioned within the protective garment or protective accessory itself.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred embodiment of the present invention is described below with reference to the accompanying drawings, in which:

FIG. 1 is a top view of an embodiment of the first layer of ballistic fabric of the composite fabric assembly of the present invention, having portions thereof cut at least partially into strips of material;

FIG. 2 is a side perspective view of an embodiment of the composite fabric assembly of the present invention;

FIG. 3 is a side view of a further embodiment of the layering of the fabric layers for the composite fabric assembly of the present invention;

FIG. 4 is an exploded view of an embodiment of examples of designs or shapes which have been punched at least partially therethrough either the first or the second layer of ballistic fabric;

FIG. 5 is an exploded view of further embodiments of examples of designs or shapes which have been punched at least partially therethrough either the first or the second layer of ballistic fabric; and

FIG. 6 is a rear view of one embodiment of a protective garment or accessory into which the composite fabric assembly of the present invention can be inserted.

DESCRIPTION OF THE PREFERRED EMBODIMENT

In the preferred embodiment, and with reference to FIG. 2, the improved composite fabric assembly of the present invention is designated in its entirety by the reference numeral 1. The protective composite fabric preferably comprises at least one layer of base fabric 5 designed to be adjacent to the skin or outer surface of the wearer 20, with at least one overlying first ballistic layer 3 connected thereto. At least one second ballistic layer 7 is then connected to the first ballistic layer 3 to form the composite fabric assembly 1 having spike and edge blade resistant properties for use with humans and animals, in the manufacture of protective garments which are lightweight, flexible, fire retardant, durable and reliable, and which can provide protection of body parts in addition to the head, neck, chest/torso region, as well as arms, legs and feet. It will also be understood that if a plurality of fabric layers are utilized, ballistic resistant can also be obtained.

It should be noted that the term “Edge Blade”, as used by the U.S.A. NIJ (National Institute of Justice, Washington, D.C.) refers to high quality, commercially machined edged knife blades, and that “Spike” refers to lower quality knife blades and spike style weapons that have been improvised from other materials.

It will, of course, be understood that more than one layer of base fabric 5 could be utilized, and preferably multiple layers are utilized. In an exemplary embodiment, 14 layers are utilized. The base fabric can be selected from, but is not limited to, a ballistic grade fabric, a fabric that is a woven fabric, a non-woven fabric, a dimensionally stable fabric, a fire retardant fabric, a high density fabric and a high tensile strength fabric. Two possible examples of materials that could be utilized are Microflex™, manufactured by Teijin, and Kevlar Correctional™, manufactured by Dupont, though other variations to this are possible also, as would be apparent to one skilled in the art. This layer of base fabric 5 is designed to be adjacent to the skin or outer surface of the wearer 20. Preferably, the layer of base fabric 5 will be thin, flexible, and able to fold and bend easily.

At least one layer of ballistic fabric 3 is connected to the layer of base fabric 5, the layer of ballistic fabric 3 being cut into strips of material 4, as shown in FIG. 1, and being connected to the layer of base fabric 5 in an overlapping manner whereby the layer of base fabric 5 is substantially covered. Possible examples of suitable materials that could be utilized are SRM™, manufactured by Teijin, and Argus™, manufactured by Dupont, though other variations to this are possible also, as would be apparent to one skilled in the art. It will also be understood that the first layer of ballistic fabric 3 can also comprise a plurality of ballistic fabric layers. The first layer of ballistic fabric 3 is connected to the base fabric 5, by sewing, adhesive, heat or other means. Furthermore, the strips of material 4 of the first layer of ballistic fabric 3 are separated by slits 6, forming gaps, between each of the strips of material 4.

At least one second ballistic layer 7 is connected to the first ballistic layer 3 to form the composite fabric assembly 1, it being understood that more than second ballistic layer 7 could be utilized. The second ballistic layer 7 will preferably have punched, at least partially therethrough, at least one design or shape 9 thereon, examples of which can be seen in FIGS. 4 and 5, though it will be readily understood that numerous variations of designs and shapes, in addition to those shown in FIGS. 4 and 5, can be effected. The purpose of punching the designs or shapes 9 is to increase the flexibility of the layer, to prevent the rigidity thereof and increase wearability and overall comfort.

The connection of the second ballistic layer 7 to the first ballistic layer 3 can be done in an offset manner to provide protection so sharp edges do not go through the composite fabric assembly. However, in any event, due to the fact that multiple layers of fabric are assembled in a stacked relationship with one another, as can be seen in FIG. 3, protection against spike and/or bladed weapons is provided.

In a still further embodiment, the strips of material 4, and indeed any portion of the first layer of ballistic fabric 3 may also have punched thereon, at least partially therethrough, at least one design or shape 9. The spacing of the designs or shapes 9 on can be varied, as will be understood to allow more protection or more flexibility, it being understood that having a greater number of designs or shapes thereon thus leads to the composite fabric assembly having more flexibility, while lesser designs and shapes allows for greater protection. It will also be understood that combinations of shapes and designs could also be used on any of the fabric layers.

It should also be noted that either of the first layer of ballistic fabric 3 or the second layer of ballistic fabric 9 can be adjacently connected to and overlap and cover the base fabric 5, whereby the at least one layer of base fabric is covered; either of these layers can be interchanged, if desired, in construction of the composite fabric assembly. Further, one or more of layers of base fabric 5 can also be used, selectively inserted between any of the first layers of ballistic fabric 3 or any of the second layers of ballistic fabric 9, or even as a final outer layer of the composite fabric assembly that would first sustain strike force. In this manner, the at least one layer of base fabric can be interspersed at various locations throughout the composite fabric assembly.

FIGS. 2 and 3 illustrate possible variations of the stacking of fabric layers that can be effected to form the composite fabric assembly 1. FIG. 2 illustrates the skin or outer surface of the wearer 20 being covered by the layer of base fabric 5, followed by alternating, in sequence, a plurality of layers of the first ballistic layer 3 and the second ballistic layer 7. FIG. 3 illustrates the skin or outer surface of the wearer 20 being covered by the layer of base fabric 5, followed by a layer of the first ballistic layer 3 (noted as being “2” in FIG. 3), then followed by a layer of the second ballistic layer 7 (noted as being “3” in FIG. 3). These layers are then further connected to two separate stacked layers of the first ballistic layer 3, followed by three further stacked layers of the second ballistic layer 7, followed by two further layers of the first ballistic layer 3. Of course, it will be readily understood that numerous variations and combinations as to how the stacked layer construction of the composite fabric assembly 1 is assembled can be varied, as well as the total number of fabric layers that are utilized. In use, the total number of fabric layers to be utilized can be between 7-20 layers, though this can of course be varied.

Once the composite fabric assembly 1 is assembled, it can be utilized in within a protective garment or protective accessory. It should be understood that garments can include, but are not limited to, Hats, Helmets, and Liners, Face Gaiters, Scarves, Neck Dickey, Underarm Guards, Wrist Guards, Hand Guards, Jackets, Coats, Ponchos, Gloves, Mitts, Belts, Repelling harnesses and related devices, Footwear including. Insoles, shoes, runners, boots and socks, and hockey or sports protection equipment. It will also be understood that gear and accessories can include, but are not limited to, Blankets, tarps, tents, Backpacks, Bags, Cushions, Vehicle Liners, Furniture Liners, Ropes (open and closed end), and Speed Skating Short Track Bumper Pads.

In operation, the composite fabric assembly can be, for example, positioned within at least one pocket formed on a surface of the protective garment or protective accessory. This pocket can either be externally or internally located. Alternatively, the composite fabric assembly could be positioned within internal and external layers of the protective garment or protective accessory.

FIG. 6 is an illustration of utilizing the composite fabric assembly within a protective garment or protective accessory. In the example shown in FIG. 6, there is shown a rear view of a protective hockey pant, having pockets formed thereon for receiving the composite fabric assembly, though it will of course be understood that numerous variations to this are possible, including, but not being limited to, various kinds of equipment, apparel and accessories, as previously noted. There is shown in FIG. 6 a thigh pocket 13, a groin pocket 15, a knee pocket 17 and a protective Achilles tendon pocket 21. All of the pockets could be enclosed and sealed with various conventional means, such as detachable snap 19, though of course closures such as Velcro™ could also be utilized. In the version shown in FIG. 6, the hockey pants are of course designed to have stirrups 23 to be placed under the feet of the wearer.

In a still further embodiment, the composite fabric assembly can be selectively sealable and enclosed in a membrane-like pouch/shell made of a rip-stop or similar fabric with properties including protection against UV-ultra violet light, and being water proof or water resistant. This outer shell protects the materials which make up the composite fabric assembly. The shell would then be inserted and positioned within the protective garment, external carrier or protective accessory.

The present invention has been described herein with regard to preferred embodiments. However, it will be obvious to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the invention as described herein. 

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
 1. A composite fabric assembly comprising: a) at least one layer of base fabric, the at least one layer of base fabric being constructed and arranged to be worn adjacent to a user; b) at least a first layer of ballistic fabric having portions thereof cut at least partially into strips of material; c) at least a second layer of ballistic fabric connected to the at least a first layer of ballistic fabric, and punched at least partially therethrough to form at least one design or shape thereon; and wherein either of the at least a first layer of ballistic fabric or the at least a second layer of ballistic fabric are adjacently connected to and overlapping the at least a first layer of base fabric, whereby the at least one layer of base fabric is covered.
 2. The composite fabric assembly of claim 1, wherein the base fabric is selected from the group consisting of a ballistic grade fabric, a fabric that is a woven fabric, a non-woven fabric, a dimensionally stable fabric, a high density fabric and a high tensile strength fabric.
 3. The composite fabric assembly of claim 1, wherein the at least a first layer of ballistic fabric or the at least a second layer of ballistic fabric is connected to and overlaps the at least one layer of base fabric in an offset manner.
 4. The composite fabric assembly of claim 1, wherein the at least a first layer of ballistic fabric and the at least a second layer of ballistic fabric are connected to each other in an offset manner.
 5. The composite fabric assembly of claim 1, wherein the at least a first layer of ballistic fabric comprises a plurality of ballistic fabric layers.
 6. The composite fabric assembly of claim 1, wherein the at least one layer of base fabric comprises a plurality of base fabric layers.
 7. The composite fabric assembly of claim 1, wherein the at least a second layer of ballistic fabric comprises a plurality of ballistic fabric layers.
 8. The composite fabric assembly of claim 1, wherein the composite fabric assembly comprises multiple layers of each of the at least one layer of base fabric, the at least a first layer of ballistic fabric and the at least a second layer of ballistic fabric, arranged in a stacked relationship with one another.
 9. The composite fabric assembly of claim 1, wherein the composite fabric assembly is constructed and arranged for use within a protective garment or protective accessory.
 10. The composite fabric assembly of claim 9, wherein the composite fabric assembly is positioned within at least one pocket formed on a surface of the protective garment or protective accessory.
 11. The composite fabric assembly of claim 1, wherein the at least a second layer of ballistic fabric is connected to the at least a first layer of ballistic fabric in an offset manner.
 12. The composite fabric assembly of claim 9, wherein the composite fabric assembly is positioned within the protective garment or protective accessory.
 13. The composite fabric assembly of claim 1, wherein the at least a first layer of ballistic fabric is punched at least partially therethrough to form at least one design or shape thereon.
 14. The composite fabric assembly of claim 1, wherein the composite fabric assembly is selectively sealable and enclosed in a membrane-like pouch/shell having UV-ultra violet light, and water resistant properties.
 15. The composite fabric assembly of claim 8, wherein the at least one layer of base fabric is interspersed at various locations throughout the composite fabric assembly.
 16. A protective garment or protective accessory constructed and arranged to receive a composite fabric assembly for protecting a body region of a wearer, the assembly comprising: a) at least one layer of base fabric; b) at least a first layer of ballistic fabric having portions thereof cut at least partially into strips of material; c) at least a second layer of ballistic fabric connected to the at least a first layer of ballistic fabric, and punched at least partially therethrough to form at least one design or shape thereon, wherein either of the at least a first layer of ballistic fabric or the at least a second layer of ballistic fabric are adjacently connected to and overlapping the at least a first layer of base fabric, whereby the at least one layer of base fabric is covered; and whereby the protective composite fabric assembly is positioned within at least one pocket formed on a surface of the protective garment or protective accessory, or positioned within the protective garment or protective accessory itself.
 17. The protective garment or protective accessory of claim 16, further comprising a biasingly resilient strap for securing the protective garment or protective accessory to the body region of the wearer.
 18. The protective garment or protective accessory of claim 16, wherein the body region is selected from the group consisting of head, neck, face, arms, fingers, back, upper torso, lower torso, groin, legs, Achilles region, feet and toes.
 19. A method for assembling a composite fabric assembly for use in a protective garment or protective accessory comprising: providing at least one layer of base fabric; providing at least a first layer of ballistic fabric; and providing at least a second layer of ballistic fabric connected to the at least a first layer of ballistic fabric, and; cutting portions of the at least a first layer of ballistic fabric at least partially into strips of material; punching, at least partially therethrough, portions of the at least a second layer of ballistic fabric to form at least one design or shape thereon; connecting either of the at least a first layer of ballistic fabric or the at least a second layer of ballistic fabric to the at least one layer of base fabric so as to be in an adjacent and overlapping relationship therewith, whereby the at least one layer of base fabric is covered; and positioning the composite fabric assembly in the protective garment or protective accessory.
 20. The method of claim 19, wherein assembling the composite fabric assembly further comprises arranging multiple layers of each of the at least one layer of base fabric, the at least a first layer of ballistic fabric and the at least a second layer of ballistic fabric, in a stacked relationship with one another, and wherein the step of connecting the at least a second layer of ballistic fabric to the at least a first layer of ballistic fabric further comprises connecting the at least a second layer of ballistic fabric to the at least a first layer of ballistic fabric in an offset manner. 